At LeanGo, our mission is to empower companies with the knowledge and tools to implement lean methodologies, driving sustainable improvements in cost quality and delivery. One of our most remarkable success stories is with Terrasmart eBOS, where Jeff Cross, Plant Manager, shared his journey of transformation through our training program. 

Challenges Before Lean Training 

Before engaging with LeanGo, Terrasmart eBOS was already striving to enhance production. However, their rapid growth posed significant challenges: 

• Keeping pace with the increasing demands became difficult. 

• Ensuring changes were sustainable and embraced by everyone in the team. 

• Reducing lengthy learning curves by breaking down processes into manageable steps for faster training. 

Implementing Lean Methodologies 

With these challenges in mind, Jeff and his team embarked on LeanGo's Lean Lego Simulation training course. The training focused on practical, hands-on learning and fostering a team-oriented approach. Key improvements made post-training include: 

• Designing and setting up two flow lines and an assembly cell. 

• Validating the first flow line and planning for further material handling waste reduction. 

• Implementing new delivery methods and point-of-use storage solutions. 

Outstanding Outcomes 

The outcomes of LeanGo’s training have been nothing short of transformative for Terrasmart eBOS: 

• Achieved record high numbers in production and shipments last month, up 98%, without adding new personnel. 

• Newer team members are integrating and learning faster, with the training cell leading the way. 

• Significant reduction in cycle times, with the longest station time reduced to a 75% improvement. 

• Production throughput has exceeded previous records, and they can operate efficiently with fewer people. 

• Customer service and delivery times have improved significantly, tripling their delivery capacity. 

Sustaining Progress 

Sustainability of progress has been a key focus at Terrasmart eBOS: 

• Continuous training and improvement plans are in place, keeping momentum high as everyone sees tangible benefits. 

• Flow line changes have been led by production leader Braeden and a fully trained team, fostering ownership and continuous improvement. 

• Establishing a new standard with built-in flexibility allows for ongoing enhancements and adaptability. 

Positive Impact on Team and Culture 

The changes have had a profound impact on the team and overall culture: 

• Initial success sparked widespread interest and enthusiasm for training and making improvements. 

• The positive atmosphere and shared achievements continue to drive further engagement and innovation. 

Advice for Others 

Jeff’s advice to others considering lean training is clear: 

"Don't delay in investing time for training. Despite initial concerns about meeting production demands, the quick payoff and ability to dedicate time for changes have been immensely beneficial." 

Appreciation for LeanGo’s Approach

Terrasmart eBOS has found immense value in LeanGo’s approach: 

• Hands-on and team-oriented training sessions were well-received. 

• Practical application of learning, such as using Legos to simulate production changes, helped solidify concepts. 

• Establishing a common language for improvement facilitated quicker, more inclusive changes. 

Conclusion:

LeanGo has played a pivotal role in helping Terrasmart eBOS realize their potential. The hands-on training, practical applications, and sustained improvements have transformed their production process, setting new benchmarks for cost quality and delivery. As they look forward to further growth, a possible refresher course this summer will ensure they continue to surge ahead. 

At LeanGo, we are proud to have been a part of Terrasmart eBOS's success story and remain committed to helping other companies achieve similar transformational outcomes.